40,320 Pieces - Memorable Disney Moments

The Biggest Puzzle in the World

Assemble the world’s largest puzzle!

Are you a Disney fan and an avid puzzler? Then “Memorable Disney Moments” is the puzzle for you! With over 40,000 pieces, “Memorable Disney Moments” is confirmed by Guinness World Records as the largest commercially made puzzle in the world, both in number of pieces and overall size.

The 40,320 piece puzzle measures 22 feet long and over 6 feet wide – a huge puzzle with an amazing Disney design. The image showcases 10 scenes from the most popular Disney films and will take you on a little journey through time from “Snow White and the Seven Dwarves” in 1937 to “The Lion King” in 1994.

But the illustrations are not 100% identical with the original: a hidden Mickey Mouse symbol has snuck itself into each scene. To discover all ten, you have to look very carefully…

Watch the video about the World Record Puzzle

Watch the video about the World Record Puzzle

Watch the video about the World Record Puzzle

The World's Biggest Puzzle in the Making

Step 1: Illustrator at Work

A Disney authorized illustrator designs each individual scene by hand. After spending about 650 hours at his computer, his completed work is sent to Ravensburger.

Step 2: First Design Inspection

Two editors inspect the first color proof of the design. They need to ensure that the color reproduction is correct, that it doesn't have blurrs or blemished, and that the transitions between the scenes are optimal. Once the design is consistent with their vision, they give the approval to begin the printing process.

Step 3: Production Begins

The scene of Snow White & Co is in the pre-printing stage. In preparation for offset printing, the operator sets up the exposure for each of the four printing plates

Step 4: Preparing for Print

Here, the print operator inspects the color of each individual printing plate. After a ten minute set up time, the printer is ready to go.

Step 5: Paper by the Pallet

During the set up process, the offset printer is filled in preparation for series production. A special linen paper is used that is purchased directly from the Black Forest.

Step 6: Print Inspection

An employee inpects the images to ensure the color replication is correct and to ensure the printing plates are correctly calibrated.

Step 7: Up to Speed

One color after the other, the printer rolls the yellow, cyan, magenta, and black ink over the white paper. This printer is capable of printing up to 18,000 images per hour.

Step 8: Onto the Board

The lamination machine precisely adheres the images to the Ravensburger board. Our high quality cardboard ensures that the pieces will continue to fit together after countless uses without air pockets, image lift, or puzzle dust.

Step 9: 10 Times Through

The process is repeated for all 10 puzzles. Once they are all completely printed and applied to the boards, they are ready to be sent through the press to be cut.

Step 10: Shaping the Form

The craftsman designs the blade to be used to cut the puzzle in the press. It takes him about 400 hours to design each unique curve.

Step 11: Under Pressure

The boards are then put into the puzzle press where they are pressed onto the blade with about 2 thousand tons of force. Each section of the puzzle is cut into 4,032 pieces then falls into a plastic bag for packaging.

Step 12: Last Quality Inspection

Is the bag properly sealed? Are the pieces all cut correctly? To ensure everything is in order, all 10 bags are put through personal inspection just before packaging.

Step 13: All Packaged and Ready to Go!

This 44 pounds of puzzle is all packaged and ready to be shipped all over the world.

Step 14: From the Warehouse to the World

The puzzles are placed in the warehouse for storage in preparation to be shipped to puzzlers throughout Germany, Europe, and the rest of the world.